Optimal tool path searching and tool selection for machining of complex surfaces

This article deals with the calculation of curvature of free-surfaces for the use in processes of machining. The calculation is realized in Matlab environment. Objects with free-surfaces are mainly used in machine engineering, design, automotive and aerospace industry etc. The manufacturing of such surfaces are realized on multi-axes machining centres, where the tool path controlling is crucial process. It is necessary to ensure collisionfree states between tool and workpiece as well as between tool and peripheral shape of machined surface. It is described in this article how the surface imported into Matlab is divided into different areas. The criteria of the division is based on Gaussian curvature of a surface. Such areas of the surface are then possible to machine by an optimal tool with optimal radius that is obtained from the curvature calculation. All these calculations are done in Matlab and results are verified by practical machining on the 5-axis machining centre. The machining of the whole surface by one tool was compared to machining of divided areas by different tools. The impact on the length of tool paths during the machining process is summarized in conclusion.